Radiator: Service and Repair

REMOVAL
1. Disconnect negative cable from battery.

WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.

2. Drain cooling system.
3. Remove air intake resonator.
4. Remove coolant reserve system tank to filler neck tube hose.
5. Disconnect fans from the connector located on the left side of the fan module.
6. Remove the Coolant Recovery System (CRS) tank retaining screw from the upper radiator closure panel crossmember.
7. Disconnect the upper radiator mounting screws from the crossmember. Disconnect the engine block heater wire if equipped.
8. Remove the upper radiator closure panel crossmember.
9. Remove air cleaner assembly.
10. Disconnect automatic transmission oil cooler lines at radiator and plug.
11. Disconnect inlet and outlet hoses from the radiator. Remove the lower hose clip from the fan module.

Air Conditioning Condenser Mounting Fasteners:

12. Remove A/C condenser fasteners and separate the condenser from the radiator. Verify the condenser is supported in position.
13. Remove A/C filter/dryer mounting bracket, 2 bolts to the fan module, and 2 nuts to the filter/dryer.
14. Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes during removal.

INSTALLATION
1. Be sure the air seals are in position before radiator is installed. Slide radiator down into position behind closure panel. Seat the radiator with the rubber isolators into the mounting holes provided, with a 10 lbs. force.
2. Install A/C filter/dryer and mounting bracket onto fan module.

Air Conditioning Condenser Mounting Fasteners:

3. Install Air Conditioning Condenser onto the radiator.
4. Unplug and connect automatic transmission oil cooler lines to radiator.
5. Install inlet and outlet radiator hoses (including coolant reserve hose) and connect the fan motor electrical connection.
6. Install air cleaner assembly.
7. Install the upper radiator closure panel crossmember.
8. Install the upper radiator mounting screws. Tighten radiator mounting bolts to 12 Nm (105 inch lbs.). Connect the engine block heater wire if equipped.
9. Install the Coolant Recovery System (CRS) tank retaining screw to the upper radiator closure panel crossmember.
10. Install air intake resonator.
11. Fill cooling system.
12. Connect negative cable to battery.